Method of making a pulley structure



Aug. 18, 1964 J. w. ANDERSON 3,144,705

METHOD OF MAKING A PULLEY STRUCTURE Original Filed Oct. 22, 1959 .AINVENTOR L i JOHN W. ANDERSON :Fig '7 WW MJL aux@ ATTORNEY United StatesPatent O M 3,144,705 METHOD F MAKING A PULLEY STRUCTURE .lohn W.Anderson, 578 Broadway, Gary, Ind. Original application Oct. 22, 1959,Ser. No. 848,031, now Patent No. 3,059,487, dated Oct. 23, 1962. Dividedand this application Feb. 26, 1962, Ser. No. 175,898

4 Claims. (Cl. 29-159) This invention relates to motion-convertingdevices and more specifically to an improved pulleylike member for usein converting linear motion to oscillatory motion.

This application is a division of my copending application Serial No.848,031, tiled October 22, 1959, now Patent No. 3,059,487, issuedOctober 23, 1962.

It has long been conventional practice to manufacture pulleys by adie-casting process or by a stamping operation. When the stamping methodis used, two mating parts are formed from sheet metal, which parts areassembled together face to face in such a way that a cable or the likepassing around the periphery oi the pulley is disposed between theflared outer portions of the mating parts. This last-rnentioned form ofpulley has many disadvantages even though it is considered to be ahighly desirable and inexpensive way of making a pulley. The chiefdisadvantage lies in the fact that the cable nests in the depressioncreated by the face-to-face fastening of the mating parts of the pulleysuch that a reasonable load on the cable wedges the cable between themating parts thereby stopping any further relative movement between thecable and pulley. Even though the cable might not fail, it becomesfrayed due to the excessive pinching and wedging of the parts. When thecable enters and leaves the surface of the pulley in the generalvicinity oi the same side of the pulley, the separate reaches of thecable abrade one another causing further fraying that contributes tobreaking of the cable.

In my U.S. Patent 2,901,764, issued September l, 1959, a circularpulleylike member is illustrated for converting the reciprocating linearmotion of a motor-driven link member to the oscillatory motion of theshaft and wiper arm used on the windshield of current-type automobiles.The pulley illustrated in that patent is shown as circular in shape,although it is within the context of the patent that the pulley could beof some shape less than a full circle as long as the operativeperipheral portion is substantially smoothly curved in shape. In my saidpatent, a pair of grooves are formed about the periphery or" the pulleysuch that one reach of a cable member is seated in one groove andanother adjoining reach of the cable is switched over and is seated inthe other groove whereby the cable encircles the pulley. As therespective reaches of the cable enter and leave the pulley, they passeach other in spaced relationship so as not to come in contact with andabrade each other. The forming of the parallel grooves in the peripheralsurface of the pulley adds considerable expense to the cost ofproduction of the pulley.

It is, therefore, a principal object of this invention to provide animproved pulleylike structure that overcomes the disadvantages of theprior art and at the same time maintains the more desirable featuresthereof,

It is an object of this invention to provide an improved pulleylikestructure made of relatively inexpensive stamping members.

It is a further object of this invention to provide an improvedpulleylike structure wherein the two body portions are identical andmade from the same die.

It is still a further object of this invention to provide an improvedpulleylike structure wherein the circumference of the pulleylikestructure does not define a full circle, ellipse or the like, but ratheris cut ott beyond that por- 3,l44,705 Patented Aug. 18, 1964 ICC tionthat is not needed for operation of the resulting system.

And a still further object of this invention is to provide a pulleylikestructure having only a partially circular shape or a partiallyelliptical shape or the like, which structure requires less clearancespace for installation and operation in a system.

It is another object of this invention to provide an improved pulleylikestructure having a separate race member that is inexpensive tomanufacture, simple to install in the pulleylike structure, and highlyefficient in use.

It is still another object of this invention to provide an improved racemember for a pulleylike structure that can be formed with any number ofspaced cable receiving channels or grooves for maintaining overlappingreaches of a cable out of abrading contact with each other.

And another object of this invention is to provide an improved racemember for a pulleylike structure that has a novel retaining means forpositioning said race member relative to the body of the pulleylikestructure.

Other objects and advantages of the invention will become apparent afterthe description hereinafter set forth is considered in conjunction withthe drawing annexed hereto.

In the drawing:

FIGURE 1 is a perspective view of a pulleylike member encompassing thefeatures of my invention;

FIGURE 2 is a blown-apart perspective View of the elements of myinvention as illustrated in FIGURE l;

FlGURE 3 is an enlarged cross-sectional view taken along the lines 3 3of FIGURE l;

FIGURE 4 is a top plan view of my invention as used in conjunction witha reciprocating link member, as shown further in FIGURE 6;

FIGURE 5 is a cross-sectional view taken along the lines 5 5 of FIGURE6;

FlGURE 6 is a side elevational view partially in section of my inventionshown in connection with a reciprocating link member;

FIGURE 7 is a View taken along the lines 7-7 of FIGURE 6; and

FIGURE 8 is a cross-sectional view taken along the lines 8-8 of FIGURE6.

Referring to the drawings and particularly FIGURES 1-3 thereof, thenumeral l@ designates an assembled pulleylike member without theassociated cables adapted for use therewith. The pulleylike member 1t)is comprised of a pair of identical mating parts l2 and 13, each parthaving a ilat body portion 14 formed of sheet metal or the like to whichan annular llange 15 is integrally formed about the periphery thereof. Apair of oppositely offset upwardly extending ears 17 and 18 are formedintegrally with each body portion 14 and are spaced apart a shortdistance in the plane of said body portion. Formed through anappropriate part of each body portion 14 is a shaped aperture 20, thewalls of which are adapted to engage with a correspondingly shaped endportion 2l. of a drive shaft 22 when assembled for use. The center ofthe aperture 2li is located, in the illustrated form, at the geometricalcenter of the semicircular peripheral arc so that the distance from thecenter of the aperture 2i) to the contacting surface of a cable on thepulleylike member is constant. It is to be understood that the center ofthe aperture 2t) could be eccentrically placed with respect to the edgeof the pulley without departing from the spirit of this invention.

A circular aperture 24 is formed through one preselected part of eachbody portion 14 and a transversely formed hollow lug Z5 extends in adirection opposite to the direction of the peripheral flange 15. Theposition of each lug 25 and each aperture 24 is such that when the bodyportions 14 of the two mating parts 12 and 13 are brought together faceto face, the lug 25 of one part will pass through the aperture 24 of theother part and vice versa. The two parts 12 and 13 are made from thesame die and are identical in construction so that reversing one of theparts makes an equal and opposite part for assembling with the firstpart to form the pulleylike member.

The annular anges 15 formed on the edges of the parts 12 and 13 areshaped in such a way that the base or bottom wall portion 27 is formedsubstantially flat and extends substantially at a right angle to thebody portion 14 of each part. The outer end of the base or bottom wall27 ows smoothly into the side wall 28 which in cross section (FIGURE 3)is curved first outwardly and then inwardly such as to create an outeredge 30 overhanging or overlapping a limited portion of the bottom wall27 of the flange 15.

An elongate rim or raceway member 32 is stamped or formed from sheetmaterial or the like and has a pair of spaced-apart grooves 33 and 34shaped into the flat surface thereof in substantially parallel relationto each other along the length of said member. A pair of ears 36 extendoutwardly beyond the side edges 37 of each end portion of the rim member32 in such a way as to form longitudinally spaced abutments 3S on eachside thereof. The rim member 32 is shaped in a substantially circularform with a radius of curvature substantially equaling the radius ofcurvature of the peripheral edge of the mating parts 12 and 13. Inassembling the parts of the pulleylike member, the rim member 32 isplaced upon the bottom wall 27 of one part 12 with the abutments 3Soverhanging the ends of the ange. The other part 13 is brought intoengagement therewith by passing the respective lugs through therespective apertures 24 with the abutments 38 on the opposite side ofthe member engaging with the ends of the flange on said part 13.

A simple peening operation on the outer end of each lug 25 folds thematerial of the lug over into engagement with the outer face of therespective parts 12, 13 so as to hold the parts assembled relative toeach other and to hold the rim member 32 in operative position withrespect to the parts.

With the parts 12 and 13 assembled together about the rim member 32, theoverhanging edges of the flanges 15 prevent the rim member 32 fromradial removal with respect to the pulleylike member while the ears 36on the rim member 32 prevent relative rotatable movement between the rimmember 32 and the body portions 14 of parts 12, 13. The rim member 32 isadapted to seat upon the respective at bottom walls or seats 27 of theanges 15 of parts 12 and 13 to form a backing for the rim member for apurpose to be obvious hereinafter.

The pulley of the instant invention has many uses in many differentdevices but as herein shown, for the purposes of illustration, it isassembled with a reciprocating link member 40 which can be attached to amotor or the like. The pulleylike member 10 is rigidly attached to theend of the pivot shaft 22 for simultaneous movement therewith about thelongitudinal axis of said shaft. A cable member 42 has one end portion43 fastened by means of lug 44 to the outer end of the link 40. Fromsaid end portion 43 the cable 42 extends into engagement with one groove33 in the rim member 32 of the pulley and partially encircles thepulley. The cable 42 passes between the oppositely disposed ears 17 and18, engages in the other groove 34 in the rim member, and passes therest of the Way around the pulleylike member 10. The other end portion45 of the cable is fastened by means of clip 46 to an intermediateportion 47 of the link. A stop lug 48 is fastened to an intermediateportion of the cable 42 and ts between the inner edges of the ears 17and 18 so as to prevent sliding movement of the cable relative to thepulley.

As the link member 40 is reciprocated in a linear path, first oneportion of the cable wraps itself into one of the grooves in the rimmember of the pulley as another portion of the cable -Llnwraps withrespect to the other groove in said rim member. The wrapping andunwrapping of the cable relative to the grooves in the pulley causes thepulley to oscillate about the axis of the shaft. Since each end of thecable rides in its own groove in the rim member, there is no abradingaction between overlapping portions of the cable nor is there bindingbetween the cable and the depression created by the assembly of themating parts of the pulley.

ln the illustrated form of the invention, the curved side walls 28 ofthe flanges 15 of the pulley engage in the shaped walls of the endportion of the link 40 so as to add stability and smoothness to themotion conversion from the link to the pivot shaft.

It is believed to be obvious that the mating parts 12 and 13 of thepulley can be readily stamped from tlat sheet stock such as metal or thelike in a highly eicient and inexpensive operation. Likewise, the rimmember 32 can be formed in a simple stamping operation wherein the ears36 forming the abutments 38 and the grooves 33 and 34 are simultaneouslyformed in one operation.

It is to be understood that the pulleylike member could be made in acomplete circle or in any desired segment of a circle, as well as beingshaped as an ellipse or the like, without departing from the spirit ofthe invention. The extent or shape of the peripheral surface dependsupon the contact required and the amount of angular movement to beimparted to the shaft 22.

Having thus described my invention, it is obvious that variousmodifications may be made in the same without departing from the spiritof the invention; and, therefore, I do not wish to be understood aslimiting myself to the exact form, construction, arrangement andcombination of parts herein shown and described.

I claim:

1. A method of constructing a cable-driven assembly comprising:

forming body members with a peripheral portion describing anincompletely closed curve,

forming from flat stock an elongate member with a pair of longitudinallyextending substantially parallel cable-receiving grooves,

curing said elongate member to conform generally to the incompletely`closed curve peripheral portion of said body members and applying thecurved elongate member to the incompletely closed curve peripheralportion of said body members and securing said body members togetherwith said elongate member therebetween,

and bending ends of the curved elongate member for holding relationshipwith ends of said incompletely closed curve peripheral portion toprevent relative peripheral movement therebetween. 2. A .method ofconstructing a cable-driven assembly comprismg:

forming from flat stock a pair of body portions with peripheral angeportions extending partly therearound and describing an incompletelyclosed curve,

securing said body portions together to form a support member with aperipheral flange portion extending partly therearound and describing anincompletely closed curve,

forming from tlat stock an elongate member with a pair of longitudinallyextending substantially parallel cable-receiving grooves,

curving said elongate member to conform generally to the incompletelyclosed curve peripheral ange portion of said support member and applyingthe curved elongate member to the incompletely closed curve peripheralange portion of said support member,

and bending the ends of the curved elongate member inwardly between theends of said incompletely closed curve peripheral flange portion of saidsupport member to secure the curved elongate member to the supportmember.

3. The method of constructing a pulley comprising the steps of:

forming a pair of body members into a shape wherein a flange portionextends around less than the complete periphery of each body,

forming shoulder means adjacent the termination of each flange portion,

curving an outer portion of each ange inwardly to form a radialload-carrying surface on its radial most periphery,

shaping a rim member to conform generally to the periphery of the bodymembers adjacent said flange portions and terminating its ends short ofa closed curve,

placing said rim member between said flange portions and securing thebody members together to form a pulley with the curved outer portions ofeach flange facing inwardly,

and deforming portions of the rim member into holding relationship withsaid shoulder means.

4. The method of constructing a pulley comprising the steps of forming apair of body members each having anges around a portion of the peripherythereof,

forming each flange with a seat for receiving a rim and curving an outerportion of each flange laterally to define a radial load-carryingsurface,

shaping a rim member to conform to the circumferential shape of saidseat,

placing the rim member between the anges of the pair of body members,

securing the body members together with outer portions of each saidflange curving toward the other,

and bending ends of the rim member toward each other for holdingrelationship with portions of the flanges so as to prevent relativeperipheral movement therebetween and for directing portions of a cablefrom one bent end toward the other bent end.

Cantrell May 10, 1949 Howell Oct. 20, 1953

1. A METHOD OF CONSTRUCTING A CABLE-DRIVEN ASSEMBLY COMPRISING: FORMINGBODY MEMBERS WITH A PERIPHERAL PORTION DESCRIBING AN INCOMPLETELY CLOSEDCURVE, FORMING FROM FLAT STOCK AN ELONGATE MEMBER WITH A PAIR OFLONGITUDINALLY EXTENDING SUBSTANTIALLY PARALLEL CABLE-RECEIVING GROOVES,CURING SAID ELONGATE MEMBER TO CONFORM GENERALLY TO THE INCOMPLETELYCLOSED CURVE PERIPHERAL PORTION OF SAID BODY MEMBERS AND APPLYING THECURVED ELONGATE MEMBER TO THE INCOMPLETELY CLOSED CURVE PERIPHERALPORTION OF SAID BODY MEMBERS AND SECURING SAID BODY MEMBERS TOGETHERWITH SAID ELONGATE MEMBER THEREBETWEEN, AND BENDING ENDS OF THE CURVEDELONGATE MEMBER FOR HOLDING RELATIONSHIP WITH ENDS OF SAID INCOMPLETELYCLOSED CURVE PERIPHERAL PORTION TO PREVENT RELATIVE PERIPHERAL MOVEMENTTHEREBETWEEN.